[PPT] - Sl d Sludge Handling Automation Sludge Handling Automation Sl d H PowerPoint Presentation

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Sl d H dli A t ti Sl d H dli A t ti Sludge Handling Automation Sludge Handling Automation

MECH/MECA 440 B– Senior Project Spring 2010 Final Design Presentation Tuesday, May 11th, 2010 y, y ,

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Design Team Members Design Team Members

Mechatronic Engineering Mechanical Engineering Ahmad Aladdasi Carlos Cabrera Ahmad Aladdasi Carlos Cabrera Mechatronic Engineering Mechatronic Engineering Nik Tkachenko Keith Lindauer Faculty Advisor : Dr. Ramesh Varahamurti

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Industry Sponsor Industry Sponsor

USS POSCO INDUSTRIES

“ T d t b i i th t id “…To conduct business in a manner that provides maximum value to our customers, owners, and

employees. To be the Safest, Most Competitive

Flat Rolled Steel Company” Flat Rolled Steel Company

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Project Background Project Background

Water

Water utilized at the facility is utilized at the facility is treated and treated and ret rned to San Joaq in ret rned to San Joaq in ri er/ Ne York ri er/ Ne York returned to San Joaquin returned to San Joaquin river/ New York river/ New York Slough. Slough.

Alum is introduced in the process to meet

Alum is introduced in the process to meet state clarity state clarity requirements, creating sludge. requirements, creating sludge.

Sludge is sent to an Oil Separation Unit

Sludge is sent to an Oil Separation Unit (OSU) (OSU) (OSU). (OSU).

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OSU Clarifiers

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Project Background Project Background Project Background Project Background

S l t V l Clarifier Valve Selector Valve Flush Valve Flush Valve Pump Current Pumping System

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Project Need Project Need

Pump the sludge from the Pump the sludge from the clarifiers clarifiers to the to the Pump the sludge from the Pump the sludge from the clarifiers clarifiers to the to the Oil Separation Unit without human assistance Oil Separation Unit without human assistance

Clarifiers OSU

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Goal Statement Goal Statement

A t t th i ti d t th A t t th i ti d t th Automate the existing procedure to pump the Automate the existing procedure to pump the correct consistency of sludge from the correct consistency of sludge from the Cl ifi t th Oil S ti U it (OSU) Cl ifi t th Oil S ti U it (OSU) Clarifiers to the Oil Separation Unit (OSU). Clarifiers to the Oil Separation Unit (OSU).

Pneumatic Actuator PLC

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Customer Requirements Customer Requirements Customer Requirements Customer Requirements

The Design Solution Must :
Automate the sludge pumping system
Automate the sludge pumping system
Switch between clarifiers
Utilize Emergency Switch
Back flush

Back flush

The Design Solution Should :
Human Machine Interface
Would be Nice :

Would be Nice :

Positive displacement pump analysis

SLIDE 10

Engineering Specifications & Engineering Specifications & Targets Targets

Requirements Specification Metric Method/Device Target Range Conditions

Pump Sludge Flow Rate GPM Flow meter 50 ± 10 GPM Minimum 100 ± 10 GPM Maximum Regulate Sludge % Solids in Water Solution PPM Turbidity Meter 20% ± 5% solids Minimum 60% ± 5% solids Maximum Pressure in Pipes Pressure PSI Pressure Gauge < 150 PSI Maximum

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Design Solution Design Solution

PLC

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Design Solution Design Solution Design Solution Design Solution

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Design Solution Design Solution Design Solution Design Solution

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Design Solution Design Solution Design Solution Design Solution

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Design Solution Design Solution

Nusonics Flow meter

PLC Interface With the System

Series 90 G.E Programmable Logic Controller 115 VAC Power Supply Optical Turbidity Meter Centrifugal Pump Rugged Pressure Sensor Electro-Mechanical Actuator

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Design Solution Design Solution Design Solution Design Solution

PLC PLC Genius Blocks

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Design Solution Design Solution

Open South Clarifier Valve Open North Clarifier Valve Open Flush Valve Full Valve Full Close Clarifier Valve Stop Pump, Close all Valves

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Design Solution Design Solution

Close Flush Valve Close Clarifier Valve Stop Pump, Close all Valves

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Design Solution Design Solution

Stop Pump, Close all V l Valves

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Fabrication Changes Fabrication Changes Fabrication Changes Fabrication Changes

Design Changes

Actuators

Actuators – – Now Pneumatic Now Pneumatic Valves Valves Now Butterfly Now Butterfly

Valves

Valves – Now Butterfly Now Butterfly

Pump

Pump – – Only 1 Required Only 1 Required

Si l ti f T bidit M t Si l ti f T bidit M t

Simulation of Turbidity Meter

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Testing Overview Testing Overview Testing Overview Testing Overview

Tests/Checks

Assembly/Wiring Check

Assembly/Wiring Check Engineering Requirements Test Engineering Requirements Test

Engineering Requirements Test

System Isolation Test

System Isolation Test

Emergency Stop Test

Emergency Stop Test Emergency Stop Test Emergency Stop Test

Automatic Test

Automatic Test

Semi

Semi-

Automatic Test

Automatic Test

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Test Results Test Results Test Results Test Results

Assembly/Wiring

PASS

System Isolation

PASS

Emergency Stop

PASS

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Test Results Test Results Test Results Test Results

Requirements Specification Metric Method/Device Test Results (Automatic) Test Results (Semi- Automatic) Conditions 18 G 16 G Mi i

Target Range

Pump Sludge Flow Rate GPM Flow meter 18 GPM 16 GPM Minimum 65 GPM 49 GPM Maximum Regulate Sludge % Solids in Water Solution PPM Turbidity Meter N/A N/A Minimum N/A N/A Maximum Pressure in Pipes Pressure PSI Pressure Gauge 60 PSI 53 PSI Maximum

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Discussion of Results Discussion of Results Discussion of Results Discussion of Results

Requirements Specification Metric Method/ Device Target Range Test Results (Automatic) Test Results (Semi- Automatic) Conditions Fl 50 10 GPM 18 G 16 G Mi i Pump Sludge Flow Rate GPM Flow meter 50 ± 10 GPM 18 GPM 16 GPM Minimum 100 ± 10 GPM 65 GPM 49 GPM Maximum Regulate Sludge % Solids in Water Solution PPM Turbidity Meter 20% ± 5% solids N/A N/A Minimum 60% ± 5% solids N/A N/A Maximum Pressure in Pipes Pressure PSI Pressure Gauge < 150 PSI 60 PSI 53 PSI Maximum

SLIDE 25

Budget Budget

Unit Price Quantity Final Unit Price Quantity Price Centrifugal Pumps

$1,125 2 $2,500

4” - #150 Pipe

$5/ft 100 $500

Available to Use, (Already Purchased Parts) G.E. PLC + 2 Blocks

$5,000 1 $5,000

2” Actuated butterfly flow screw

$2301 1 $2,301

4” pneumatic Actuated Butterfly valve

$2301 3 $6,903

2” Gate valve

$1000 2 $2,000

4” WCB check Gate

$500 3 $1,500

4 WCB check Gate

$ $ ,

Nusonics inc. Flow meter

$10,000 1 $10,000

4” Butterfly gate valve

$500 2 $1000

4” Garloc expansion joints

$550 1 $550

Parts Needed Viatran 548 Pressure Gauge

$200 1 $200

Turbidity Meter and Assembly

$8,000 1 $8,000

Labor Design

Mech. Eng.

$ 34.97/hour 100 $ 3,497

Design

Meca. Eng.

$ 36.8/hour 400 $ 14,720

Manufacturing

$ 50/hour 25 $1,250

Overhead @ 40% per labor hour

$8,980

Benefits @ 37% per labor hour

$8,307

Total Cost = $77,208 Parts on Hand = $32,254 Donated Labor + Expenses = $21,200 + 17,287 = $36,754 Final Cost = $77,208 – $69,008 = $ 8,200

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Additional Content Additional Content Additional Content Additional Content

Unique problems encountered

Turbidity Meter(Shipping Times)

Simulate using current supply

Simulate using current supply

Simulate using current supply

Simulate using current supply

Suggestions for the future

Change injection valve to variable position Change injection valve to variable position

Change injection valve to variable position

Revise Specifications

Refine % Solids once turbidity meter is

Refine % Solids once turbidity meter is installed installed

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Conclusion Conclusion Conclusion Conclusion

All the design specifications are met

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Acknowledgements Acknowledgements

USS

USS-Posco Posco

USS

USS Posco Posco

Frank

Frank Martucci Martucci Mike Atwood Mike Atwood

Mike Atwood

Natalie

Natalie Tkachenko Tkachenko Todd McHugh Todd McHugh

Todd McHugh

Ron Hatchel

SLIDE 29

QUESTIONS ? QUESTIONS ? QUESTIONS ? QUESTIONS ?

OSU Clarifiers